04removal Installation

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[EMM Book1 TOC] TB3 - 117

[Chapter 72 TOC] ENGINE MAINTENANCE MANUAL SPAF–TB3EMM–1
TABLE OF CONTENTS
Title Section,
Sub-Section, Page
Subject
072.00.00
ENGINE - REMOVAL/INSTALLATION .......................................................................................................... 1

TASK CARD NO. 401................................................................................................................................. 1
ROCEDURE: Unpacking of Engine ...................................................................................................... 1
TASK CARD NO. 402................................................................................................................................. 3
ROCEDURE: Installation of Engine ..................................................................................................... 3
Figure 401 Engine Handling Points ..................................................................................................... 4
Figure 402 Рог Reference When Transferring Engine Prom Support to Mounting Trolley ......................... 7
Figure 403 Engine Removal/Installation .............................................................................................. 8
Figure 404 (Sheet 1 of 3) Engine Mounting Points ............................................................................. 11
List of Parts Required for Mounting Engine on Helicopter (The final List is enclosed in the case with
mounting parts supplied with each engine) ....................................................................................... 17
Table 401 ....................................................................................................................................... 17
Table 401, continued ....................................................................................................................... 18
Table 401, continued ....................................................................................................................... 19
Table 401, continued ....................................................................................................................... 20
TASK CARD NO. 403............................................................................................................................... 22
PROCEDURE: Removal of Engine ..................................................................................................... 22
Figure 405 Removal of Vibration Pick-Up Mounting Bracket (For Single-Rotor Helicopters) ................... 23
EFEECTIVITY:
ALL
072.00.00
Nov 25/09
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ENGINE - REMOVAL/INSTALLATION
PAGES
TO M. S. TASK CARD No. 401 4О1/4О2
MS. ITEM ROCEDURE: Unpacking of Engine
CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.)
ACTIONS BY
1. Prior to proceeding with engine unpacking, carry out visual inspection of the engine wooden shipping
container (Ref. Fig. 1002) and ascertain that it is not damaged and the seals are intact.
NOTE. Peculiarities of engine unpacking from the metal shipping container are given in Appendix 5.
2. Unscrew the cover (l)-to-base (8) attachment unit nuts (7).

Attach the lifting slings of the hoist to four shackles (6) of the cover and lift it from the base of the container.
CAUTION! WHILE REMOVING THE COVER OF THE CONTAINER, EXCERSIZE CARE AND AVOID SKEWNESS.
3. Loosen nuts (40) and unscrew bolts (43) (Ref. 072.00.00, Fig. 1001, sheet 4 of 4) of the middle support
of the transportation stand. Cut the polyethylene film slip cover near the seam (Ref. Fig. 1001) and carefully
roll it down.
Remove the bags containing silica-gel deny drat or, the humidity indicators, and the paraffined paper.
4. The engines are supplied with their compressor casing, combustion chamber casing, turbine casing, fourth
support assembly housing, and exhaust stack either painted or unpainted, their joints being painted.
Inspect the engine visually for any signs of damage. Check against; the accompanying documents the
validity of the preservation term, the completeness of the engine set, the availability of the tools kit,
mounting parts, and the individual set of spares.
It is allowed to mount in one helicopter the engines with the above mentioned assemblies both painted
and unpainted.
EFEECTIVITY: 072.00.00
ALL Nov 25/09
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TB3 - 117 [EMM Book1 TOC]
SPAF–TB3EMM–1 ENGINE MAINTENANCE MANUAL [Chapter 72 TOC]
TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS
1. Open-end wrench, S = 30x32 mm

2. Lifting hoist
3. Scissors
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PAGES
TO M. S. TASK CARD No. 402 403 to 420.1/420.2
MS. ITEM ROCEDURE: Installation of Engine
CORRECTIVE CHECKED
ACTIONS BY
1. Perform installation of the engine with the main gear box mounted in its place in accordance with the
helicopter documents and taking into account the requirements of the present Task Card. Perform
installation of the engine, with the main gearbox mounted in its place in compliance with the helicopter
service documentation with due regard for the Note to Table 401.
2. Prior to mounting the engine, clean the engine bay to remove foreign particles, dust and dirt and wash all
components of the helicopter oil system. No flushing of the oil cooler is required if helicopter total operating
time is less than 100 hours.
CAUTION: CHANGE THE OIL COOLER BEFORE MOUNTING A NEW ENGINE WHICH REPLACES THE ENGINE
REMOVED FOR CHIPS DETECTED IN THE OIL SYSTEM
3. Attach the engine sling to holes (2) (Ref. Fig. 401) provided in front flange (1) and lugs (3) located on free
turbine NGV fourth assembly housing (4)
4. To transfer the engine from the stand to the mounting trolley (Ref. Fig. 402) or to the shipping container
support, proceed as follows:
(a) Connect the engine lifting sling and pre-tension its cables.
(b) Unscrew nuts (1) of bolts (4) attaching side trunnions (3) and nuts (8) of bolts (5) attaching rear
support assembly (6).
(c) Lift the engine from the transportation support and install it together with the front and rear support
assemblies on the mounting trolley.
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CORRECTIVE CHECKED
ACTIONS BY
1. Front Flange
2. Hole
3. Lug
2 4. Free Turbine N G V Assembly Housing
Figure 401 Engine Handling Points
OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.) CORRECTIVE CHECKED

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ACTIONS BY
CAUTION! 1. TO PREVENT CHIPPING OF THE LOCATING SHOULDER AND
BREAKDOWN OF THE SIDE POSTS OF THE FIRST SUPPORT ASSEMBLY HOUSING, LIFT THE
ENGINE FROM TOE TRANSPORTATION SUPPORT OR MOUNTING TROLLEY ONLY WHEN THE
FRONT MOUNT AND REAR TRUNNION ARE CONNECTED.
2. DISCONNECT (CONNECT) TOE FRONT MOUNT AND REAR TRUNNION ONLY ON THE ENGINE
LIFTED IN THE POSITITON CONVENIENT FOR WORK, WHILE OBSERVING TOE SAFETY
PRECAUTIONS.
5. Prepare the engine for installation, using for this purpose the dolly or the stand of the transportation
container
5.1. Install the fire extinguish ant spray manifold in compliance with the directions laid down in the helicopter
service documentation; in this case, the clearance between the spray manifold (especially the clearance
between its nuts) ant the engine parts should be not less than 5 mm.
CAUTION! WHEN INSTALLING AND REMOVING THE FIRE EXTINGUISH ANT SPRAY MANIFOLD, AVOID
DENTS AND SCRATCHES ON THE ENGINE CASINGS AND PIPES.
6. Operations to Be Performed Prior to Installing Engine
6.1. Accomplish the engine external de-preservation (Ref. Task Card No. 301).
6.2. Remove dummy pick-up (7) (Ref. Fig. 404), blank plug (35) and install the gas generator rotor speed
transducer and the oil pressure pick-up. Couple the electrical connectors of these sending units to the
electric wire harness, observing the marking, and coat the connectors with primer ЭП-076 and then with
aluminum enamel ЭП-140 (Ref. Task Card No. 703).
NOTE. On some engine models, minimum oil pressure switch is installed, and the tee to the oil pressure
pick-up is replaced (rearranged) by the shortened helicopter tee (Ref. Book 3).
CORRECTIVE CHECKED
ACTIONS BY
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6.3. Remove the blanks from the engine inlet and outlet, air bleed valves and the protective bands from the
air starter; keep the removed blanks and protective bands as a set and install them on the engine when
sending it from the using agency.
6.4. Connect the air intake duct of the helicopter to front flange (4) (Ref. Fig. 404).
6.5. Install the engine electronic governor (engine limit governor) on the helicopter in compliance with the
directions laid down in 073.15.04 (073.16.04), Task Card No. 201 (Ref. Book 3).
7. Installation of Engine
7.1. For disconnecting the engine front mount and the rear trunnion from the engine, proceed as follows:
(a) Connect the engine hoisting sling to the engine and pre-tension the sling cables (Ref. Fig. 401).
(b) Unscrew nuts (1) (Ref. Fig. 402) of bolts (4) attaching side trunnions (3) and nuts (8) of bolts (5)
attaching rear support assembly (6) and lift the engine to a position convenient for work.
(c) Unscrew nuts (38) (Ref. Fig. 1001) of bolts (29) attaching front mount (25) and nuts (15) of bolts
(11) attaching rear trunnion (13). Remove the front mount and rear trunnion.
CAUTION! TO PREVENT CHIPPING OF THE LOCATING SHOULDER AND BREAKDOWN OF THE SIDE
POSTS OF THE FIRST SUPPORT ASSEMBLY HOUSING, DO NOT CHANGE THE SEQUENCE OF
OPERATIONS INDICATED IN ITEMS «Ь» AND «с».
7.2. Prior to coupling the engine with the main gearbox, carry out the following operations:
(a) Examine the splines of drive shaft (1) (Ref. Fig. 403) for condition, make certain that they are free
from chipping and other damage, make certain that sealing ring (2) is free from damage.
CAUTION! DO NOT MOVE THE DRIVE SHAFT TO AVOID AXIAL MISALIGNMENT OF THE SHIM.
SHOULD THE DRIVE SHAFT BE SHIFTED OR REMOVED, MEASURE DIMENSION «А» (Ref.
072.53.00, Task Card No. 203).
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2 7
1 8
1. Nut 5. Bolt
2. Washer 6. Rear Support
3. Side Trunnion 7. Washer
4. Bolt 8. Nut
Figure 402 Рог Reference When Transferring Engine Prom Support to Mounting Trolley
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18
17
17
1. Drive Shaft
2. Sealing Ring 9
3. Flange
4. Engine Load-Bearing Cone
5. Bolt
6. Sphere Housing
7. Retaining Washer 5 6
8. Rut
9. Vain Gearbox 10 11
10. Sphere Cover 7 8
11. Bearing Spherical Journal
12. Rut
13. Retaining Washer Correlation line
14. Sealing Ring
15. Splined. Bush
16. Bolt Correlation line
17. Engine Mounting Points Correlation line
18. Front Flange
2 1
3 16
4
15 14
13 12
Figure 403 Engine Removal/Installation
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CORRECTIVE CHECKED
ACTIONS BY
(b) Disconnect sphere housing (6) from main gearbox (9) and mount it on flange (3) of engine load-
bearing cone (4). Install bolts (5) into the holes, install retaining washers (7) on the bolts, tighten
attachment nuts (8) and lock them, if possible, by the tabs bent to the different flats. The correctness
of mounting of the sphere housing is constructional ensured by displacement of one of the holes in
the joint flanges of sphere housing (6) and load-bearing cone (4) of the engine and by installation of
all twelve bolts (5).
(c) Coat the spherical surfaces of sphere housing (6) and the spherical journal of bearing (11) with a
thin layer of grease HK-50 and the splines of drive shaft (10) with a thin layer of oil used in the engine
oil system.
(d) Connect two vertical rods and one short rod (from the side of the adjacent engine) to engine
mounting attachments (17) on front flange (18) of the engine and fuselage attachment points.
7.3. When coupling the engine with the main gearbox:
Carefully engage drive shaft (1) with splined bush (15) of the main gearbox overrunning clutch, shifting
back the engine secured on three front rods and, if necessary, turning the drive shaft by the blades of
the free turbine.
CAUTION: 1. THE TOLERABLE ANGULAR MISALIGNMENT OF THE AXES OF THE ENGINE AND MAIN
GEARBOX OVERRUNNING CLUTCH IN THE COURSE OF COUPLING THE ENGINE WITH THE
MAIN GEARBOX IS 30 MIN (WHICH IS ENSURED BY SECURING THE ENGINE ON THE
THREE FRONT RODS, ADJUSTED AS DESCRIBED IN THE HELICOPTER MAINTENANCE
MANUAL).
2. NEVER RESORT TO WOBBLING OR TAPPING WHEN COUPLING THE ENGINE WITH THE
MAIN GEARBOX.
7.4. Align the holes made in the flanges attaching sphere housing (6) to sphere cover (10), having turned the
sphere cover by hands until the correlation lines on the housing and cover of the sphere are aligned.
Install all bolts (16), retaining washers (13) and tighten nuts (12).
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CORRECTIVE CHECKED
ACTIONS BY
CAUTION: DO NOT BEND UP THE TABS OF THE RETAINING WASHERS.
The correctness of mounting of the sphere cover is ensured constructional by displacement of one of the
holes in the joint flanges of the sphere housing and sphere cover and by installing all bolts (16).
NOTE: The location marks made on the flanges of the sphere housing and sphere cover are intended to
facilitate alignment of the holes during assembly.
7.5. Check the angular position of the engine with respect to the main gearbox by checking the misalignment
of the location marks made on spherical journal (11) of the bearing from the side of the main gearbox
and on sphere cover (10). The misalignment of the location marks with respect to each other should be
within ±1.5 mm.
8. Operations to Be Carried Out After Installation of Engine
8.1. Carry out the engine to main gearbox alignment check (Ref Task Card No. 606) and adjust it, if required.
8.2. Lock nuts (12) of bolts (16) attaching sphere cover (10).
8.3. Install the second short rod without tension.
8.4. Attach to the engine and secure:
(a) The pipe returning oil from the first support assembly to connection (36) in the oil tank (Ref. Fig.
404).
(b) The helicopter air offtake pipe, which should be connected either to flange (9), having first unsafetied
and removed screws (12) attaching blank (11) or to flange (14), having first unsafetied screws (18)
attaching plug (16).
CAUTION: WHEN CONNECTING THE PIPE TO FLANGE (9), IT IS PERMISSIBLE TO REPLACE 23 mm DIA
WASHER (10) BY 25 mm DIA WASHER. DO NOT INSTALL WASHERS OF ANY OTHER
DIAMETER. SIMULTANEOUS AIR OFFTAKE FROM FLANGES (9) AND (14) IS INTOLERABLE.
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3
2
5 4
9
10
11
12
16
15 8
1 7, 1 8
14
18a
1 8b
7
13
1. Air Starter Flange 8. Minimum Oil Pressure Switch MCTB- 13. Drain Valve Connector
2. Anti-Icing System Electrical Connector 2.5 (on some engine models the 14. Air Bleed Flange
3. Hole for Attachment of Vibration Pick-Up pressure switch is not installed, Ref. 15. Gasket
Bracket Book 3) 16. Plug
4. Front Flange 9. Air Bleed Flange 17. Washer
5. Hot Air Bleed Flange 10. Washer 18. Screw and Nut
6. Master Electrical Connector 11. Plug 18a. Washer 78890308
7. Oil Pressure Dummy Pick-Up 12. Screw 18b. Washer 78890309
Figure 404 (Sheet 1 of 3) Engine Mounting Points

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22 23
21
19
20 24
25
28
26
27
29
19. Flange 25. Connection Supplying Control Pressure to

20. Sealing Ring Power Synchronizer of Adjacent Engine
21. Free Turbine Speed Control Lever 26. Exhaust Stack
22. Gas Generator Speed Control Lever 27. Coupling Clamp
23. Shutdown Valve Control Lever 28. Engine-to-Main Gearbox Joint Flange
24. Connection Supplying Control Pressure to Power 29. Temperature-Sensing Probe Cooling Air
Synchronizer from Adjacent Engine Supply Conduit Attachment Flange

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CORRECTIVE CHECKED
ACTIONS BY
30. Upper Oil Pump Block Oil

Outlet Connection
31. K -82 Terminal Block
32. Air Bleed Valve 31
35
33. Connection Delivering Oil
from Oil Pump Block to Oil
Cooler 30
34 Connection Supplying Oil
from Oil Tank (On some
engine models this
connection is turned thru 180 32
deg, Ref. Book 3) 36
35. Plug 33
36. First Support Assembly Oil
37
Outlet Connection
37. Connection Returning Oil
from Oil Pump Block to Oil 34
Tank (On some engine
models there is no oil return
from oil pump block to oil
tank, Ref. Book 3)

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CORRECTIVE CHECKED
ACTIONS BY
(c) Helicopter hot air offtake pipe to flange (5).
(d) Fuel supply pipe to flange (19).
CAUTION: PRIOR TO CONNECTING THE PIPE, ASCERTAIN THAT SEALING RING (20) IS INSTALLED ON
THE PUMP FLANGE.
(e) The drain pipe to drain valve connection (13).
(f) The pipe (with the installed chip detector) returning oil to the oil cooler - to oil pump block connection
(33) and - pipe returning oil to the oil tank - to connection (37) (on some engine models, connection
(37) is blanked off), (Ref. Book 3).
(g) The pipe delivering oil from the oil tank to connection (34) of the oil pump block.
(h) The pipes of the power synchronizing system, for which purpose proceed as follows:
Connect power synchronizer connection (25) of the engine being installed to connection (24) of the
adjacent engine and connection (25) of the power synchronizer of the adjacent engine to connection
(24) of the engine being installed.
CAUTION: AVOID TENSION OF THE CONNECTIONS AND FLANGES OF THE ENGINE WHEN CONNECTING
THE PIPES.
(i) The air supply pipe to flange (1) on the air starter.
(j) The hose returning oil to the oil tank from connection (30) of the upper oil pump.
(k) The master electrical connector and electrical connector (2) to the hot air valve and electrical
connectors of the ДЧВ and ДТА transducers.
(l) The engine control rods to the following fuel control unit control levers:
- Gas generator rotor speed control lever (22).
- The free turbine speed control lever (21) (Ref. Notes , Item 3).
- Valve control lever (23) of the fuel control unit shut-off valve.
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CORRECTIVE CHECKED
ACTIONS BY
NOTES: 1. When the engine control levers in the cockpit are set against the stops, the control rods of
the engine and shut-off valve should be adjusted so as to ensure the following clearances:
— A 0.5 to 1-mm clearance between the gas generator rotor speed control lever and the
stops of the fuel control unit.
— A 0.5 to 1.5-mm clearance between the shut-off valve control lever and the fuel control
unit stops.
2. The travel of the free turbine speed control lever of each engine should be adjusted to be
1 2
within angles of (41  2 )° and (93 1 )°.
The difference in travel of the levers of both engines should within 2 deg.
3. On some engine models, lever (21) -is not in use (Ref. Book 3).
(m) The compensating wires of the thermocouples measuring the compressor turbine inlet temperature
and temperature controller to terminal block (31).
8.5. Measure the impedance of the thermocouples circuits directly at the terminals of the temperature Adjust impedance of
controller. The impedance must be within the limits of (2.5±0.5) ohms. thermocouples and the
compensating leads right
at the terminals of the
temperature controller.
8.6. Install and secure the conduit supplying cooling air to the temperature-sensing probe, to fuel control unit
flange (29) (Ref. Task Card No. 802).
NOTE. When mounting the previously installed air conduit, observe the procedure detailed in the
helicopter Maintenance Manual.
8.7. Install the vibration pick-up complete with the mounting bracket into hole (3) provided in engine front
flange (4) on the RH side of the engine (looking forward).
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CORRECTIVE CHECKED
ACTIONS BY
NOTE. On the engine installed on the coaxial-rotor helicopters, the bracket with the vibration pick-up
should be mounted in accordance with the helicopter Maintenance
Manual.
8.8. Connect the flexible hoses tapping air from air bleed valves (32).
8.9. Mount the tail pipe onto exhaust stack (26) and fasten it with coupling clamp (27) observing the
requirements described in Task Card No. 204, 072.58.00.
Install DPD (if necessary) according to the instructions given in Helicopter Maintenance Manual, at the
same time the requirements given in Task Card No. 306 shall be observed.
8.10. Carry out the operations within the scope of the preflight maintenance (periodic inspection) in
compliance with the directions laid down in the Maintenance Schedule.
8.11. Accomplish de-inhibiting of de-preserve the oil and fuel systems (Ref. Task Card No. 302).
8.12. Start the engine (Ref. Task Card No. 501), allow it to idle for a period of 3 to 5 min and then shut it
down (Ref. Task Card No. 504).
NOTE. As some quantity of oil may remain in the fuel system of the engine after de-inhibition, the first
start of the engine may be impeded. Therefore, in case of an abortive start, dry motor the
engine (Ref. Task Card No. 502) and then attempt another start.
8.13. Inspect the engine and engine systems (Ref. Task Cards Nos 601 and 602) and eliminate the defects
revealed during the inspection.
8.14. Test the engine (Ref. Task Card No. 505) and carry out the necessary adjustments.
8.15. Change oil in the engine oil system.
8.16. Examine and wash the oil filter (Ref. 072.90.02, Task Card No. 202).
8.17. Examine and wash the filtering element of the fuel filter (Ref. 073.11.04, Task Card No. 204).
8.18. Examine and wash the fuel filters of the fuel control unit (Ref. 073.12.05, Task Card No. 604) and engine
electronic governor actuator (Ref. 073.16.10, Task Card No. 205).
8.19. Perform the test of the engines concurred operation (Ref. Task Card No. 506).
8.20. Perform the operations within the scope of the preflight preparation (periodic inspection) in accordance
with the Maintenance Schedule.
8.21. Perform a check flight with a newly-installed engine and test of the engine operation in flight (Ref. Sub-
Section «Engine — Description and Operation», Para 2.3).
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CORRECTIVE CHECKED
ACTIONS BY
8.22. Perform the operations within the scope of the post flight preparation as described in the Maintenance
Schedule.
8.23. Inspect the oil filter (Ref. 072.90.02, Task Card No. 202).
8.24. Check the engine and main gearbox for alignment (Ref. Task Card No. 606).
List of Parts Required for Mounting Engine on Helicopter (The final List is enclosed in the case with mounting parts supplied with each
engine)
Table 401
Designation
Qty,
Name Usage
Drawing No., OCT Standard pc
For mounting of duct feeding air to

7884.2420 ______ Shroud with clutch 1 temperature-sensing probe (the shroud is
supplied in disassembled state)
7884.2440 ______ Air conduit 1 temperature-sensing probe (the shroud is
7884.2810 ______ Flange with shroud 1 temperature-sensing probe (the shroud is
014-017-19-2-043-A OCT
2267A-13-2 Sealing ring 1 temperature-sensing probe (the shroud is
1 00980-80
034-040-36-2-043-A OCT
1 00980-80
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CORRECTIVE CHECKED
ACTIONS BY
Table 401, continued
Designation Qty,
Name pc Usage
Drawing No., OCT Standard
038-042-25-2-043-A OCT 1
00980-80
021 -024-19-2-043-A OCT 1
00980-80
(3)-6-14-Chem. Pas. OCT 1 3148A-6-14-182AT-Chem.
Screw 4 temperature-sensing probe (the shroud is
31505-80 Pas.
1-6-12-Chem. Pas. OCT 1
3406A- 1-6-12-Chem. Pas. Washer 4 temperature-sensing probe (the shroud is
34508-80
7821.1530 — Bracket 1 For attachment of vibration pick-up
Ю-1-КцОСТ 1 33207-89 3315 А- 10-Кд Nut 1 For attachment of vibration pick-up
10-Chem. Pas. OCT 1 34523-
3464A-10-Chem. Pas. Washer 1 For attachment of vibration pick-up
80
For attachment of electric wire to vibration
7821.0421 — Clamp 1
pick-up
3-4 Кд OCT 1 031521-80 3162А-3-4-КД Screw 2 For attachment of the clamp
To be fitted under the nut attaching the

9K53-1590 — Locking washer 2
vibration pick-up
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CORRECTIVE CHECKED
ACTIONS BY
Designation Qty,
Name pc Usage
Drawing No., OCT Standard
To be fitted und the clamping collar attaching

7857.0720 — Sealing cord 1
the tail pipe to the exhaust stack
7817.0262 — Distance ring 1 For installation of the dust protection device
For attachment of the oil pressure pick- up

7889.0398 — Washer 4 (installed under dummy pick-up (7), Ref. Fig.
404)
For attachment of the oil pressure pick- up
7889.0399 — Washer 4 (installed under dummy pick-up (7), Ref. Fig.
404)
M04.450.94 -— Straight adapter 1 For installation on the terminal block
M04.450.95 — Straight adapter 1 For installation on the terminal block
60K50-1383 — Bolt 1 For attachment of the engine to the main gear
6-2 Chem. Phosh. Oxid. OCT 3315A-6-2-Chem. Phosh.

Nut 1 For attachment of the engine to the main gear
1 33202-89 Oxid.
9K53-1501 — Washer 2 For attachment of the engine to the main gear
Adapter with CC-78 chip For installation into the pipe returning oil to the
0780679740 — 2
detector oil cooler
[Main Menu]
CORRECTIVE CHECKED
ACTIONS BY
Designation
Qty,
Name Usage
Drawing No., OCT Standard pc
On some engine models, the plug is installed on the

7884.0461 ______ Plug 1
air duct instead of the П-77 temperature bulb
For sealing between the adapter and the flange of the

0240507201 ______ Gasket 1
chip detector
ЗЗМ5Ы6-12.2-1.5 ______ Sealing ring 1 For sealing of the connection with the housing flange
NOTE: Parts 7884.2420, 7884.2440, 7884.2810, 7884.0461, 7821.1530, 0780679740 are supplied only with new engines delivered to the helicopter
Manufacturer. When replacing the engines in service, reuse the parts removed from the old engines. In this case, the Data Sheet for assembly
0780679740 shall be taken from the Log Book of the engine to be removed and placed into the Log Book of the helicopter and assigned to the
helicopter. The assigned service life and the calendar time of parts are equal to the assigned life and the calendar time of the helicopter.
Plug (1) (Ref. Fig. 804) and connection (20) may be missing on some engine models.
Parts 7884.2420, 7884.2440, as well as connection (20) on some of the engine models may be replaced by respective helicopter components (Ref.
the helicopter documents). Parts 7821.1530, 7821.0421, 10-1-Кд OCT 1 33207-89, 10-Chem. Pas. OCT 1 34523-80 are not supplied with the engines
designed for installation on the coaxial-rotor helicopters.
[Main Menu]
CORRECTIVE CHECKED
ACTIONS BY
1. Engine hoisting sling 1. Safety wire

2. Hoist (of not less than 600-kg lifting capacity) 2. Oil used in engine lubrication system
3. Open-end wrench, S = 8 x10 mm 3. Grease HK-50
4. Open-end wrench, S = 10 x12 mm
7. Side-cutting pliers
8. Combination pliers
[Main Menu]
PAGES
TO M. S. TASK CARD No. 403 421 to 425/426
MS. ITEM PROCEDURE: Removal of Engine
CORRECTIVE CHECKED
ACTIONS BY
1. Remove the engine in compliance with the directions laid down in the helicopter Maintenance Manual, with
due regard for the requirements of the present task card.
1.1. Accomplish inhibiting of the oil system (Ref. 072.90.00, Task Card No. 202) and fuel system (Ref.
073.00.00, Task Card No. 201).
CAUTION! DO NOT CARRY OUT INHIBITING OF THE ENGINE OIL AND FUEL SYSTEMS ON THE ENGINES
REMOVED DUE TO SEIZURE OF EITHER 1 ONE OR BOTH ROTORS. IN CASE OF SEIZURE OF
EITHER ONE OR BOTH ROTORS, REMOVE THE AIR STARTER AND FUEL SYSTEM
ACCESSORIES FROM THE ENGINE, INHIBIT THEM AND FIT BACK TO THE ENGINE. RECORD
IN THE LOG BOOK THE INHIBITING OF THE ACCESSORIES SEPARATELY FROM THE ENGINE.
IT IS ALLOWED TO PRESERVE THE ENGINE OIL AND FUEL SYSTEMS BY MEANS OF THE
PBM-1 EQUIPMENT WITH ENGINE INSTALLED IN TRANSPORTATION STAND (DOLLY) IN
COMPLIANCE WITH THE DIRECTION DESCRIBED IN PROCESS INSTRUCTIONS SUPPLIED
TOGETHER WITH THE EQUIPMENT.
1.2. Remove DPD (if present) following the instructions given in the Helicopter Maintenance Manual, at the
same time the requirements given in Task Card No. 307 shall be observed; remove the tail pipe from
engine exhaust stack (26) (Ref. Fig. 404) observing the requirements described in Task Card No. 204,
072.58.00. Secure the coupling clamp on the flange of the exhaust stack.
1.3. Disconnect the flexible hoses at the air offtake shrouds of air bleed valves (32)
1.4. Remove bracket (4) (Ref. Fig. 405) complete with vibration pick-up from front flange (3) of the engine
(for single-rotor helicopters). For coaxial-rotor helicopters do it in accordance with the helicopter
Maintenance Manual.
CAUTION! ON SINGLE-ROTOR HELICOPTERS TO AVOID BREAKING OF WIRE (5) EXTENDING TO
VIBRATION PICK-UP (6), REMOVE THE LATTER COMPLETE WITH BRACKET (4).
[Main Menu]
CORRECTIVE CHECKED
ACTIONS BY
3
1 2
4 5 6
1. Nut
2. Washer
3. Front Flange
4. Mounting Bracket
5. Wire
6. Vibration Pick-Up
Figure 405 Removal of Vibration Pick-Up Mounting Bracket (For Single-Rotor Helicopters)
[Main Menu]
CORRECTIVE CHECKED
ACTIONS BY
1.5. Remove the conduit supplying cooling air to the FCU temperature-sensing probe (Ref. Task Card No.
802).
1.6. Unsafety and remove the following items from the engine as indicated below:
(a) Disconnect the compensating leads from thermocouple terminal blocks (31) (Ref. Fig. 404).
(b) Detach the following engine control rods:
— From gas generator speed control lever (22);
— From FCU shutdown valve control lever (23);
— From free turbine speed control lever (21).
NOTE. On some engine models lever (21) is not connected (Ref. Book 3).
CAUTION! FOLLOWING DISCONNECTION OF THE ENGINE CONTROL RODS, FIT CORRUGATED
WASHERS, BOLTS AND NUTS (USED FOR ATTACHMENT OF THE CONTROL RODS) TO THE
FCU RODS.
(c) Uncouple master el. connector (6) and el. connector (2) at the hot air valve and the respective el.
connectors at the ДТА and ДЧВ transducers.
(d) Detach the helicopter air intake pipe from flange (9) or from flange (14).
CAUTION! WHEN INSTALLING PLUG (11) ON FLANGE (9), MAKE CERTAIN THAT WASHER (10) IS
AVAILABLE.
(e) Detach the helicopter hot air bleed from flange (5).
(f) Detach fuel return pipe from flange (19).
(g) Detach drain pipe from connection (13).
(h) Detach the pipe of oil feed from the oil tank from connection (34) of the oil pump block.
(i) Detach the pipe (with the chip detector installed) of oil return to the oil cooler from connection (33)
of the oil pump block and the pipe of oil return to the oil tank from connection (37) (on some engine
models, connection (37) is blanked off, Ref. Book 3).
[Main Menu]
CORRECTIVE CHECKED
ACTIONS BY
(j) Detach the synchronizing system pipes from connections (24) of the fuel control unit and engine (25).
(k) Detach the hose of oil return to the oil tank from connection (30) of the upper oil pump (1). Detach
the air feed pipe from flange (1) of the air starter.
CAUTION! ON ALL EXPOSED CONNECTIONS, FLANGES, PLUG CONNECTORS INSTALL THE TEMPORARY
BLANKS REMOVED DURING INSTALLATION OF THE ENGINE ON THE HELICOPTER.
2. Operations to be Performed During Engine Removal

2.1. Disconnect the short rod of the engine attachment from the outward side.
2.2. Attach the engine sling (Ref. Task Card No. 402) to the housing of the turbine stage 4 NGV assembly.
Pre-tension the cables of the sling.
2.3. Detach sphere cover (10) (Ref. Fig. 403) from sphere housing (6), having unlocked and unscrewed nuts
(12) and removed bolts (16).
2.4. Disconnect three front rods from the engine front flange (18).
2.5. Uncouple the engine from the main gearbox by carefully moving the engine forward over a distance of
72 to 75 mm: measure the distance with respect to the flanges of sphere housing (6) and sphere cover
(10).
CAUTION! THE ANGULAR MISALIGNMENT BETWEEN THE ENGINE AXIS AND THE AXIS OF THE MAIN
GEARBOX OVERRUNNING CLUTCH IN THE COURSE OF UNCOUPLING THE ENGINE FROM
THE MAIN GEARBOX SHOULD NOT EXCEED 30’. PREVENT WOBBLING AND TAPPING DURING
THE ENGINE UNCOUPLING.
3. Operations to be Completed After Engine Removal
3.1. Detach sphere housing (6) from flange (3) of engine load-bearing cone (4), having unlocked and removed
nuts (8), and then install the sphere housing onto main gearbox (9), having secured it to sphere cover
(10) with bolts (5) and nuts (8). Washers (7) must have been placed under the nuts.
[Main Menu]
CORRECTIVE CHECKED
ACTIONS BY
3.2. Fit the engine to the mounting trolley or transportion stand (Ref. Sub-Section «Engine — Shipment»,
Para. 2).
3.3. Disconnect the helicopter inlet duct from front flange (4) (Ref. Fig. 404).
3.4. Remove the gas generator tachometer transmitter, oil pressure pick-up (7) and plug (35) in their places.
3.5. Install the blanks at the engine inlet and outlet and on the air bleed valves as well as the protective
bands on the air starter, removed during installation of the engine on the helicopter.
3.6. Remove the pipes of the fire extinguishant spray manifold, avoiding dents and scratches by the wrench
on the casings and pipes of the engine.
3.7. Perform the engine external preservation (Ref. Task Card No. 303).
3.8. Remove the engine electronic governor (engine limit governor), meeting the requirements laid down in
073.15.04 (073.16.04), Task Card No. 201 (Ref. Book 3).
3.9. Perform packaging of the engine (Ref. Sub-Section «Engine — Shipment»).
3.10. When replacing the engine, the chip detector is not replaced, but remains on the helicopter for the
further service (Ref. Task Card No. 402, Table 401).
NOTE. In case of chip detector service/calendar life expiry (Ref. chip detector datasheet), send it for
repair.
1. Engine sling
2. Hoist (of 600-kg lifting capacity)
7. Screwdriver
8. Combination pliers

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[Main Menu]

[EMM Book1 TOC] TB3 - 117

ENGINE - REMOVAL/INSTALLATION .......................................................................................................... 1

2. Unscrew the cover (l)-to-base (8) attachment unit nuts (7).

TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS

1. Open-end wrench, S = 30x32 mm

Figure 401 Engine Handling Points

OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.) CORRECTIVE CHECKED

Figure 404 (Sheet 1 of 3) Engine Mounting Points

19. Flange 25. Connection Supplying Control Pressure to

Figure 404 (Sheet 2 of 3) Engine Mounting Points

30. Upper Oil Pump Block Oil

Figure 404 (Sheet 3 of 3) Engine Mounting Points

(e) The drain pipe to drain valve connection (13).

For mounting of duct feeding air to

Table 401, continued

To be fitted under the nut attaching the

Table 401, continued

To be fitted und the clamping collar attaching

7817.0262 — Distance ring 1 For installation of the dust protection device

For attachment of the oil pressure pick- up

60K50-1383 — Bolt 1 For attachment of the engine to the main gear

6-2 Chem. Phosh. Oxid. OCT 3315A-6-2-Chem. Phosh.

Table 401, continued

On some engine models, the plug is installed on the

For sealing between the adapter and the flange of the

TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS

1. Engine hoisting sling 1. Safety wire

2. Operations to be Performed During Engine Removal

TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS

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